Method and device for forming a corner limited on three sides, from a plate-shaped material with an even surface

ABSTRACT

The invention relates to a method and a device for forming a corner bounded on three sides from a flat plate part, in particular sheet metal, whereby the side edges adjacent to the corner are folded back across a major part of their longitudinal extension parallel with the flat plate part and shaped on a curved path in the region in which the corner is to be formed from the folded-back side edge to the plane of the flat plate part. The pre-formed blank is then pressed at the curved transition region by means of at least one roller system ( 42 ), spanning the corner region ( 10 ) between the side edges, against a tool ( 16 ) and the corner shaped by forming the material and optionally trimmed in a cutting device.

Applicant claims priority under 35 U.S.C. §119 of Japanese ApplicationNo. 11-135224, filed May 17, 1999 and Austrian Application No. A113/2000filed Jan. 26, 2000. Applicant also claims priority under 35 U.S.C. §365of PCT/AT00/00133 filed May 16, 2000. The international applicationunder PCT article 21(2) was not published in English.

The invention relates to a method of forming a corner region from a flatsheet, in particular sheet metal plate, and a system for producing acorner region on a component from a flat sheet, bounded on three sides.

By preference, it relates to a corner-forming device adapted by means ofan adjusting mechanism to handle a box-type component whereby theadjusting mechanism is used to adjust at least one of either the tool ora roller system to a forward or retracted position in order to adjustthe tool exactly to the thickness of the box-type component, therebyobtaining a high degree of accuracy in the dimensions of the cornerregion of the box-type component.

In housings used to receive electronic instruments, communicationdevices, circuit boards and similar, the housing is made from a flatpiece of plate or a sheet. This type of housing has an opening in themain body and a cover which can be placed on the opening. The cover isdesigned for opening and closing. The cover is a box-shaped componentmade from a sheet, which is made by a plate forming process.

If a cover or similar is to be provided on the metal housing, it is madestarting from a sheet, which is shaped into a box-shaped component. Tothis end, rectangular/square cut-outs are made in the four corners of arectangular standard flat sheet metal plate. The plate is then foldedalong the four side edges in order to form the four side walls. Thecorresponding end parts of the oppositely lying side walls are thenwelded together in order to form a corner region. These corner regionsare finished by means of a polishing machine, etc.

Known methods of producing box-shaped components require the followingwork steps: cutting the parts of material out of the four corners of theplate; folding the plate along the four side edges to form the sidewalls; welding together the corresponding end parts of adjacent sidewalls to form a corner region and finishing the corner region with apolishing machine or similar.

These corner regions are therefore formed to produce box-type componentsby a series of shaping processes of this type. This approach isunacceptable from various points of view because such a large number ofwork steps complicates the process of making the corner regions of suchbox-type components and thus increases costs.

Documents DE 40 09 466 C2 and DE 196 14 517 A disclose a corner-formingmachine and a method of producing box-type components. With this device,a roll is used as a bending tool for shaping and profiling cornersstarting from a plate-shaped workpiece, in order to form a planarsurface into a corner bounded on three sides. The workpiece is held downon the tool by means of an essentially rectangular-shaped clamp. Fixedin this manner, the plate-shaped workpiece is then shaped using a toolin the form of a roller with an hour glass shape. The clamp and the toolare displaced relative to one another in the plane in which the sheet tobe formed is held. This means that the vertical side faces of the plateto be formed project beyond the parallel side faces of the clamp,including when the latter is moved into its sheet-clamping position inreadiness for shaping. Using the clamp, coverage of the corner region isprovided by the clamp but the material in this region is prevented frombeing stretched which can lead to tearing in the corner region, which isunacceptable both from an aesthetic point of view and for safetyreasons.

Accordingly, DE 196 14 517 A proposed that the oppositely lying verticalside faces of the tool and the clamp should be displaced relative to oneanother by a horizontal distance and that the face of the clamp shouldalso be inclined. The disadvantage of this approach is that thecomponent is not held firmly between the roll used to shape thecomponent and the clamp and therefore gives in this direction during therolling process, which leads to warping in the region of the flatsheet-part of the box-type component.

The underlying objective of the present invention is to propose a methodof producing corners in box-type components made from flat plates, whichenables corner regions for box-type components to be made in a widevariety of external dimensions and thicknesses whilst causing as fewproblems as possible in terms of finishing, and a system for producingsuch box-shaped components, by means of which corner regions ofdifferent designs can be produced from flat plates at the peripheralregion of pre-formed sheet-parts.

This objective is achieved by the invention, independently in each case,by means of the methods described in claims 1 to 4 and 26 and thesystems described in claims 28 to 33.

The method described in claim 1 is of advantage because the side wallsare guided across the entire height of the tool and lie against itsvertical shaping surfaces so that the component can be raised unhinderedin a perpendicular direction towards the top face of the tool even ifprojecting areas have not yet been removed.

The method outlined in claim 2 has the advantage of enabling theprojecting region between the side edges of the side walls of thecomponent to be cut off in the corner regions without burring. Due tothe fact that the cutting elements can be displaced relative to oneanother in the same plane as the guide surface, any misalignment in thetwo side walls forming the corner region can be compensated in theupward direction as the projecting area is cut off, even if tolerancesarise as a result of folding when making the side walls.

The advantage of the approach described in claim 3 is that no camberingcan occur between the side walls and the flat sheet part of thecomponent as the corner region of the side walls is shaped.

The advantage afforded by the features outlined in claim 4 is that therelative position of the shaping surfaces of the tool can be adjustedand adapted exactly to the cylinder contours of the roller system andits roll, advantageously preventing any indentation or undesirablematerial deformations in the corner region of the component surface andthe shaping region of the roller system or roll because the entireshaping process takes place across the entire forming path.

Claims 5 to 25 describe advantageous features which enable high qualitycomponents to be produced.

The process sequence described in claim 26 produces a high surfacequality without warping or any undesirable wave-type deformation in thecorner region of the material.

The process sequence described in claim 27 ensures that the transitionregion of the side walls is not misaligned in the corner region.

A system design as described in claim 28 offers an advantage because itprevents the projecting area from being deformed below the bottom faceof the tool.

Claim 29 provides an advantageous arrangement in which the cuttingelements exactly adjoin the actual contour of the side edges and can beadapted to projections in the transition region without having to bemanually re-positioned.

The solution offered in claim 30 advantageously ensures that theplate-shaped sheet part of the component stays flat.

As a result of the arrangement outlined in claim 31, surface rougheningdue to too high friction forces on the component is significantlyreduced or totally avoided whilst the cooling process and lubricatingprocess also enable higher throughput rates.

With the embodiment defined in claim 32, the shape of the cylindercontour or geometry of the roll in the roller system can be accuratelyadapted to different shapes of corner regions. A roller systemincorporating the tools needed to impart the respective shape to thecorner region can be held in readiness and it, as well as the tool, canbe adapted with little manual handling by adjusting the corner regions.

An arrangement of the type described in claim 33 enables the absoluteminimum in tolerance limits to be obtained in the shaping and transitionregion when forming the corner region, thereby obviating the need forcost-intensive finishing.

Other advantageous embodiments are described in claims 34 to 37, whichmake for cost-effective and hence economic plant and equipment forproducing components.

Claim 38 describes an advantageous embodiment as a result of which avery compact and space-saving unit can be obtained, offeringconsiderable simplifications in the control unit for implementing theshaping process and safety control to protect operating personnel.

Another possible embodiment is described in claim 39, whereby the rollused to shape the corner region can be rapidly changed so that theshaping device can be adapted to suit different shaping specifications,e.g. corner radius, etc..

Finally, the embodiment defined in claim 40 is of advantage since itenables very high clamping forces to be applied and thus producesaccurate shaping.

The invention will be described in more detail with reference toexamples of embodiments illustrated in the appended drawings.

Of these:

FIG. 1 is a simplified diagram on an enlarged scale and seen in planview of a roller system and tool as used in one embodiment of thepresent invention;

FIG. 2 is a side view of a main part of the corner-shaping device;

FIG. 3 is a plan view of a main part of the corner-shaping device and abox-shaped component;

FIG. 4 is a schematic and enlarged perspective diagram depicting a fixedand a displaceable cutting element;

FIG. 5 is an end-on view of an edge-folding machine;

FIG. 6 is a side view, seen in section, of the edge-folding machineillustrated in FIG. 5;

FIG. 7 is a schematic diagram of the corner regions of a plate beingprepared;

FIG. 8 is a side view showing the relative position of the roller systemand the tool prior to making the corner regions;

FIG. 9 is a side view of the relative position of the roller system andthe tool whilst the corner region is being produced;

FIG. 10 shows the relative position of the roller system and the toolafter the corner region has been made;

FIG. 11 shows the relative position of the cutting plate and the toolwhilst the excess (projection) is being removed from the corner region;

FIG. 12 is a perspective diagram on an enlarged scale, showing a mainregion of the box-type component before the corner regions of thebox-shaped component have been made;

FIG. 13 is a perspective diagram on an enlarged scale, showing a mainpart of the box-shaped component after the corners of the box-typecomponent have been made;

FIG. 14 is a perspective diagram on an enlarged scale, showing a mainpart of the box-shaped component, after the excess (projection) has beentrimmed from the corner region;

FIG. 15 is a perspective diagram of the box-shaped component with afinished corner region;

FIG. 16 is a schematic diagram on an enlarged scale, seen in plan view,showing one embodiment of the roller system and a tool as proposed bythe present invention;

FIG. 17 is a schematic diagram giving an end-on view of anotherembodiment of the roller system;

FIG. 18 shows the roller system illustrated in FIG. 17, seen in sectionalong the lines 18—18 of FIG. 17;

FIG. 19 is a perspective diagram of another embodiment of the tool;

FIG. 20 is a perspective diagram on an enlarged scale showing a mainpart of another embodiment of the tool;

FIG. 21a is a schematic illustration, in section, of a grooved region ofthe tool;

FIG. 21b is a schematic illustration, in section, of a grooved region ofthe tool;

FIG. 22 is a front view of another embodiment of the corner-shapingdevice;

FIG. 23 shows a plan view of the corner-shaping device illustrated inFIG. 22, seen in partial section;

FIG. 24 is a detailed illustration, in plan view, of the corner-shapingdevice;

FIG. 25 shows the corner-shaping device, seen in section along the linesXXV—XXV of FIG. 24;

FIG. 26 shows another embodiment of the cutting device proposed by theinvention, seen in section along the lines XXVI—XXVI of FIG. 27;

FIG. 27 is a schematic illustration of the cutting device illustrated inFIG. 26, seen in plan view;

FIG. 28 is another schematic diagram depicting another embodiment of thecutting device proposed by the invention;

FIG. 29 shows another embodiment of the roller system with the clampingdevice of the corner-shaping device proposed by the invention, seen insection.

Firstly, it should be pointed out that the same parts described in thedifferent embodiments are denoted by the same reference numbers and thesame component names and the disclosures made throughout the descriptioncan be transposed in terms of meaning to same parts bearing the samereference numbers or same component names. Furthermore, the positionschosen for the purposes of the description, such as top, bottom, side,etc., relate to the drawing specifically being described and can betransposed in terms of meaning to a new position when another positionis being described. Individual features or combinations of features fromthe different embodiments illustrated and described may be construed asindependent inventive solutions or solutions proposed by the inventionin their own right.

FIGS. 1 to 15 illustrate an embodiment of the present invention.

In FIGS. 2 and 3, reference number 2 denotes a box-shaped component; and4 a corner-shaping device.

As illustrated in FIG. 7, the box-shaped component 2 is made from asheet S, such as a steel plate, an aluminium plate, a stainless steelplate, a copper plate or similar, which can be shaped by rollers. As maybe seen from FIG. 15, a flat plate part 6 of the sheet S is folded alongthe four side edges to form four side walls 8. The sheet S is thereforeshaped into a box-shaped component 2. Turning now to FIG. 2, thecorner-shaping device 4 is provided with a cutting plate 14. The cuttingplate 14 is supported in the horizontal direction by a frame 12. Thecorner-shaping device 4 is also fitted with a substantiallymulti-cornered plate-type tool 16. The tool 16 is fixed on the cuttingplate 14. In the example illustrated as an embodiment here, the tool 16is a square-shaped plate. The tool 16 is secured to a bearing block 18of the cutting plate 14 by means of a centring bolt 24, pins 20 beinginserted in the bearing block 18 and additional intermediate bearings 22being disposed in between.

An adjusting mechanism 26 is also disposed on the cutting plate 14. Theadjusting mechanism 26 determines a position at which either the tool 16or the roller system 42, which will be described below, is mounted. Asillustrated in FIG. 1, the adjusting mechanism 26 comprises theintermediate bearing 22 and manually adjustable threaded spindles 28.The threaded spindles 28 are disposed between the cutting plate 14 andthe intermediate bearings 22. The threaded spindles 28 may also bemanually turned to adjust the tool 16 by a forward or retracted distance(see arrow in FIG. 1).

The tool 16 is substantially square in shape with horizontal top andbottom faces 30, 32 and four side faces 34. These four side faces 34adjoin the top and bottom faces 30, 32.

The tool 16 is designed with a shaping surface 36 for producing thecorner region 10 of a corner of the box-shaped component 2. The shapingsurface comprises the top face 30 in a corner of the tool 16 and twoside faces 34 communicating with this top face 30. The tool is alsoprovided with a cutting element 38 for trimming the excess 66 or aprojection (see FIG. 13) from the end region of the box-shaped component2 once it has been fully shaped. The cutting element 38 is arranged in aregion of a corner on a bottom face 32 of the tool 16 in which the twoside faces 34 are joined to the aforementioned bottom face 32. A drivesystem 40 for the cutting element 38 displaces the cutting element 38 inthe region of the bottom face 22 towards or away from the side wall 8 ofthe box-shaped component 2.

The corner-shaping device 4 is also provided with a substantiallyoppositely lying roller system 42 of a circular cone shape. The rollersystem 42 is displaced along the two side faces 34 forming the shapingsurface 36 at a corner of the tool 16. The roller system 42 essentiallyforms a double, circular-based cone arrangement in which a pair ofcircular-based cone parts 44 are joined to one another at their tips(vertices). The roller system 42 is displaced along the two side faces34 forming the shaping surface 36 by means of a drive system 46.

Moreover, the roller system 42 is provided with two thrust faces 48.When the roller system 42 is displaced along the two side faces 34forming the shaping surface 36, the thrust faces 48 push the excesspieces 66 or projections in a corner of the box-shaped component 2 insuch a way that the excess pieces or projections 66 are brought intodirect abutting contact with the two side faces 34 where a corner region10 is formed. The thrust faces 48 have a circular-based cone surfaceinclined in mutually facing directions but which extend continuouslytowards one another to the tip. The roller system 42 in the embodimentdescribed here is disposed and designed so that it can not rotaterelative to the two side faces 34.

The corner-shaping device 4 is also provided with a support plate 50.The support plate 50 is height-adjustable in a downward direction as faras the bottom face 32 in a corner of the tool 16. As illustrated inFIGS. 2 to 4, the support plate 50 is provided with a top and bottomface 52, 54 and two internal faces 56 disposed lying opposite said sidefaces 34. An adjusting drive 58 for the support plate 50 displaces thesupport plate 50 onto and away from the side faces 34 of the tool 16 ina reciprocating motion.

The support plate 50 has a cutting edge 60, which is arranged in aregion in which the bottom face 54 merges with the internal face 56.When the cutting edge 60 is displaced in the direction of the side faces34 of the tool 16, the tool 16 and the support plate 50 hold the sidewall 8 of the box-shaped component 2. Consequently, the cutting edge 60trims off the excess piece 66 or projection of the ready-shaped cornerregion 10 of the box-shaped component 2 in conjunction with the cuttingelement 38, as the drive system 40 for the cutting element 38 displacesthe cutting element 38 along the bottom face 32 of the tool 16.

Reference number 62 denotes a clamping device, which holds the flatplate part 6 of the box-shaped component 2 from a top face. Referencenumber 64 denotes a drive mechanism for the clamping device 62.

A description will now be given of the processing sequence in which thedevice outlined above is operated.

When the box-shaped component 2 with a corner region 10 has beenproduced using the corner-shaping device 4, the pre-processing hasalready been completed beforehand, as illustrated in FIG. 7.Specifically, the flat plate part 6 of the square plate-shaped sheet S,which has good roll-forming properties, is folded along the four sideedges to form four side walls 8. The box-shaped component 2 still hasthe excess pieces (projection) 66 which results in each corner.

As illustrated in FIGS. 5 and 6, the preliminary processing mentionedabove can be implemented using an edge-folding press 68. Theedge-folding press 68 is provided with a die 72 and a punch 74. The die72 is fixed to a main body 70. The punch 74 is displaced towards the die72.

The die 72 is made with a V-shaped grooved region 76, the height “H” ofwhich matches the height of the side wall 8 of the box-shaped component2. The grooved region 76 is provided with a shaping region 78 at bothends of this region, in other words in regions corresponding to thecorner regions 10 of the box-shaped component 2. The shaping region 78is of a height “h1”, which is greater than the height “h”. The punch 74is provided with a projection 80 having a V-shaped cross section, whichcomplements the grooved region 76. A drive mechanism 82 drives the punchto displace it towards the die 72. As illustrated in FIG. 7, theedge-folding press 78 enables the flat plate part 6 of the sheet S to befolded along its four side edges, thereby producing four side walls,using the following two components: the die 72 with the grooved region76 having the V-shaped cross section and the shaping region 78 in theregion of the two ends and the punch 74 with the projection 80 havingthe V-shaped cross section. As illustrated in FIG. 12, the shapingregions 78 of the die 72 form the excess pieces 66 or projections ineach corner of the box-shaped component 2, where the corresponding endsof two adjacent side walls adjoin one another.

Once the pre-forming process using the edge-folding press 68 iscomplete, the threaded spindles 28 of the adjusting mechanism 26 aremanually pivoted, thereby shifting the tool 16 by a forward or retracteddistance—as indicated by the arrow in FIG. 1.

As may be seen from FIG. 8, the side walls 8 at a corner of the sheet 1are positioned against the side faces 34 of a corner of the tool 16 ofthe corner-shaping device 4, the side faces 34 forming the shapingsurface 36. This being the case, the excess pieces 66 may projectoutwards beyond the tool 16, whilst the clamping device 62 is adjustedby means of the drive mechanism 64. As a result of this adjustment, theflat plate part 6 of the sheet S is applied against the top face 30 ofthe tool 16 and the sheet S is thereby fixed on the top face 30.

As illustrated in FIG. 9, once the corner-shaping device 4 is holdingthe sheet S on the tool 16, the drive system 46 displaces the rollersystem 42 in the direction indicated by the arrow (downwards in FIG. 9)along the two side faces 34 forming the shaping surface 36, whilst thethrust faces 48 of the roller system 42 are held in contact with theside walls 8 of the sheet 1. As a result, the excess piece 66(projection) standing out beyond the tool 16 is bent so far downwardsand deformed to such a degree that it sits abutting tightly against thetwo side faces 34.

The corner region 10 of the box-shaped component 2 is produced on thecorner-shaping device 4 by displacing the roller system 42 into theposition illustrated in FIG. 10.

As illustrated in FIG. 11, the adjusting drive 58 displaces the supportplate 50 towards the side faces 34 of the tool 16, whilst the tool 16and the thrust faces 48 of the roller system 42 hold the side walls 8 ofthe box-shaped component 2 in position. The drive system 40 thendisplaces the cutting element 38 along the bottom face 32 of the tool16. The cutting edge 60 of the support plate 50 then trims off theexcess piece 66 or projection from the ready-formed corner region 10 inco-operation with the cutting element 38.

As may be seen from FIGS. 14 and 15, the box-shaped component 2 withsaid corner regions is finished once the excess piece 66 or projectionhas been removed.

The adjusting mechanism 26 permits an adjustment of the tool 16 by aforward or retracted distance and thus enables the tool 16 to be dulypositioned depending on the thickness of the box-shaped component 2,obtaining a high degree of accuracy in the dimensions of the cornerregion 10 of the finished box-shaped component 2 and making thecorner-shaping device 4 highly efficient.

In addition, once the excess piece 66 or projection has been removedfrom the resultant corner region 10, the adjusting drive 58 shifts thesupport plate 50 towards the side faces 34 of the tool 16. The tool 16and the thrust face 48 of the roller system 40 then hold the side wall 8of the box-shaped component 2. Moreover, the drive system 40 displacesthe cutting element 38 along the bottom face 32 of the tool 16. At thesame time, the cutting edge 60 of the support plate 50 in conjunctionwith the cutting element 38 trims off the excess piece 66 or projection.

In comparison with known devices, the corner-shaping device 4 offers asimple process for forming the box-shaped component 2 and enables thebox-shaped component 2 to be provided with corner regions 10.Furthermore, the corner-shaping device 4 enables the corner regions 10of the box-shaped component 2 to be produced at a significantly reducedcost.

The corner-shaping device 4 used for the box-shaped component 2 asproposed by the invention is not restricted by the description givenabove and lends itself to various adaptations or modifications, as isthe case, for example, with the adjusting mechanism 26, which in thisembodiment has manually adjustable threaded spindles 28 for adjustingthe tool 16 by a forward or retracted distance. As an alternative, itwould be possible to provide a motor-driven positioning device 92.

Specifically, as illustrated in FIG. 16, the adjusting drive 58 has amotor unit, not illustrated. A conical shaft section 92-1 can bedisplaced with the motor drive in a reciprocating motion and atransmission member 92-2 connects the conical shaft section 92-1 to thetool 16. The motor unit then displaces the conical shaft section 92-1 ina reciprocating motion onto this tool, which motion is then transmittedvia the transmission members 92-2 to the tool 16, thereby adjusting adistance of the tool 16 forwards or backwards. In this manner, the motordrive enables the tool 16 to be shifted forwards or backwards by adistance, positioning the tool 16 as a result according to the thicknessof the box-shaped component 2, which means that the dimension of thecorner region 10 of the finished box-shaped component 2 will be accurateand the corner-shaping device 4 highly efficient.

As an alternative, it would also be possible to provide a pair ofpositioning mechanisms 94 in the region of the roller system 42. Inparticular, as illustrated in FIGS. 17 and 18, the positioningmechanisms 94 may comprise a pair of wedge-shaped means 94-1, a pair ofadjusting means 94-3 which slide on correspondingly inclined surfaces94-2 of the wedge-shaped means 94-1 and a pair of motion control parts94-4 to displace the corresponding adjusting means 94-3.

When the positioning mechanism 94 is activated, the motion control parts94-4 are rotated in a predetermined direction, causing the movingadjusting means 94-3 to be displaced so that the moving adjusting means94-3 slide on the inclined surface 94-2. This being the case, the rollersystem 42, which is connected to the moving adjusting means 94-3, can bepositioned relative to the tool.

In another embodiment, the positioning mechanism 94 may be providedadjacent to both, namely tool 16 and roller system 42, in order toobtain greater accuracy depending on the formatting process and toproduce the box-shaped component 2 with corners. This system affords afurther improvement in terms of ease of processing and processingquality.

Furthermore, as a result of this embodiment of the present invention,only one type of shaping surface 36 is produced with this format of thetool 16 and is so by the top face in one corner of the tool 16 and twoside faces 34 adjoining said top face. As an alternative—as illustratedin FIG. 19—it would also be possible to provide corners of thesquare-shaped tool 16 with one to four shaping surfaces 96-1, 96-2, 96-3and 96-4, e.g. the four corners themselves. These shaping surfaces couldbe made with different dimensions.

A centring bolt 24 is pulled out of a central region of said tool 16 andthe tool 16 is pivoted to a predetermined position of the tool 16 beforethe tool 16 is secured again using the pins 20 and the centring bolt 24.With this approach, the dimensions in the corner regions 10 of thebox-shaped 2 component can be easily modified, which also makes thesystem more convenient during operation.

If a bendable metal material such as aluminium is used for thebox-shaped component 2, the material will shift, for example due togravitational force, when the deformable metal material is moveddownwards as the corner regions 10 of the box-shaped component 2 arebeing formed. As illustrated in FIG. 20, the tool 16 may be providedwith a plurality of horizontal groove-shaped regions 98 in each of thecorners.

These groove-shaped regions 98 may be made as grooved regions 98-1 witha triangular cross section, as illustrated in FIG. 21a, or groovedregions 98-2 with an arcuate cross section, as illustrated in FIG. 21b.When the box-shaped component 2 with the corner regions 10 is made bymeans of the roller system 42, each corner of the box-shaped component 2will then be pressed into the groove-shaped regions 98, duly preventingany shifting of the material due to gravitational force. This embodimentavoids any problems with regard to the accuracy of the angle subtendedin the corner regions 10 of the box-shaped component 2 and also offersadvantageous options for producing corner regions 10 on a box-shapedcomponent 2.

As explained in the above description of the present invention, thepresent invention relates to a corner-shaping device 4 with an adjustingmechanism 26 for adapting to a box-shaped component 2 and a method offorming a corner bounded by three sides from a flat, plate-shapedmaterial, in particular sheet metal, in which the side edges adjacent tothe corner can be folded back parallel with the flat plate part 6 acrossa large part of their longitudinal extension and shaped, in the regionwhere the corner is to be formed, from the folded-down side edge to theplane of the flat sheet-part 6, along a curved path, wherein thepre-formed blank is formed by material deformation by means of at leastone roller system 42, spanning the corner region 10 between the sideedges, which applies the curved transition region against a die plateand the corner, characterised in that the side edges in the region ofthe corner are applied across their entire height against the peripheralend faces of the die plates. Consequently, the adjusting mechanism 26enables at least one tool 16 and a roller system 42 to be adjusted byforward or retracted distances, the tool 16 being duly positioneddepending on the thickness of the box-shaped component 2 and producingthe corner regions 10 of the finished box-shaped component 2 to a highdegree of dimensional accuracy whilst making the corner-shaping device 4very economical. In addition, compared with the devices known until now,the corner-shaping device 4 set up to produce the box-shaped component 2as proposed by the present invention offers a very simple formingprocess and enables the box-shaped component 2 to be provided withangled parts. Used to produce corner regions 10 in a box-shapedcomponent 2, such a device also makes for a significant reduction incosts.

FIGS. 22 and 23, which will be described together, illustrate anotherembodiment of a system 101 incorporating the corner-shaping device 4 forforming flat sheet materials, in particular the component 2, the samereference numbers being used for elements already described above. Asystem 101 of this type is specifically used for producing cornersbounded by three sides on the component 2, e.g. to produce safes,covers, doors, etc., for example for use in system cabinets, fromsheet-shaped blanks. A machine frame 104 of the system 101 supported ona stand surface 103 essentially consists of a bearing frame 105 disposedvertically on the stand surface 103, the plate-shaped cutting plate 14extending parallel with the stand surface 103, a guide device 107 and alocking device 108 co-operating therewith and, if necessary, a safetydoor 109 forming a safety feature which can be opened and/or closed withthe clamping device 62 specifically provided for this purposely. Theflat-shaped cutting plate 14, which for practical purposes may bedetachably joined to the bearing frame 105 or welded thereto, ispreferably fitted with an adjusting mechanism 112 and a cutting device113 on a top face 111 remote from the stand surface 103. The cuttingplate 14, which for practical purposes may be made from steel, has asubstantially rectangular basic contour with a width 114 and a length115 measured perpendicular thereto. The tool 16 co-operating with theadjusting mechanism 112 is displaceable relative to the roller system42. The guide device 107 vertically disposed on the cutting plate moreor less in the region of the half width 114 consists of two guideelements 118 spaced at a distance apart from one another. The lockingdevice 108, which is adjusted by means of the guide device 107 via alinking device 119, is formed by two plate-shaped supporting elements120 spaced at a distance apart from one another in the direction of thelength 115, the roller system 42 being arranged between them. Forpractical purposes, the roller system 42 is rotatably mounted by bearingelements inserted in the supporting elements 120. The connection of thetwo supporting elements 120 with another connecting element forms acompact unit forming the locking device 108, which is retained by theconnecting device 119. The connecting device 119 is co-operativelyconnected to a manually and/or automatically and/or semi-automaticallyoperated replacement device 121. When a fast-closing element 122, inparticular a lever 123 etc., of the replacement device 121 is operated,the connecting device 119 arranged between the locking device 108 andthe guide device 107 is shifted from a locked position into a releasedposition. Clearly, the replacement device 121 may also be built frompneumatic and/or hydraulic and/or electrical and/or electro-pneumaticand/or electro-hydraulic elements 122.

A roll 125, widely known from the prior art, mounted so as to rotateabout a central axis 124, essentially consists of two frustoconicalbodies in mirror image, tapering towards one another in a conicalarrangement and merging with one another into a rounded transitionregion. Consequently, the horizontally aligned roll 125 has a contour inthe shape of an hour glass. The gradient of the frustoconical bodiesdetermines the angle of the corner to be formed. The guide elements 118disposed vertically from the guide device 107 to the stand surface 103are detachably and/or non-detachably joined to the machine frame 104.The guide device 107, which may be cooperatively linked to one and/ormore drive units 126 enables the roller system 42 to be displacedtowards the guide elements 118 relative to at least one tool 116,enabling the folded-back edges of the component 102 to be produced. Forpractical reasons, the drive unit 126 is operated by a hydrauliccylinder because it is economical and powerful. Clearly, any other drivesystems 126 known from the prior art could be used, such as electricdrives, e.g. spindle drives, etc.

The adjusting mechanism 112 of the corner-shaping device 4, which can bedisplaced and/or positioned and/or fixed relative to the roll 125 bymeans of the drive unit 126, forms at least one plate-shaped,multi-cornered, in particular polygonal sliding element 127, practicallymade from a single piece, comprising five longitudinal end faces 128 ofthe same dimensions facing away from one another and a top face 129 andbottom face 130 extending perpendicular thereto. As may also be seenfrom FIG. 23, the tool 16 detachably and/or non-detachably mounted onthe top face 129 projects for practical purposes beyond at least onelongitudinal end face 128 facing the roll 125. By preference, aprojection 131 arranged perpendicular to the bottom face 130 standsproud in the bottom region thereof at least partially beyond thelongitudinal end face 128 facing away from the roll 125, the purpose ofwhich will be discussed in more detail below.

The cylinder contours 132, formed by the outline of the roll 125,extending towards one another in the direction of the central axis 124,subtend an acceptance angle 133 between the two cylinder contours 132and form a distance 134 between the contour of the roll 125 and the tool16 which can be adjusted by means of the adjusting mechanism 112 and setto suit the component to be formed, in particular its wall thickness. Inpractical terms, an axis of symmetry 135 running along a fictitiousdividing place between the two frustoconical bodies of the roll 125 iscongruent with an axis of symmetry 136 of the adjusting mechanism 112.The two longitudinal end faces 128 of the sliding element 127 directedtowards the cylinder contours 132 preferably run approximately parallelwith these. The two oppositely lying longitudinal end faces 128 actingas a slide track 137 extend at least at an angle to the two oppositelylying cylinder contours 132, the angle 138 subtended by the slide track137 and the axis of symmetry 136 being smaller than and/or the same asand/or bigger than half the acceptance angle 133 of the roll 125. Anapproximately V-shaped counter plate 139 adjoining the projections 131has two legs 140 widening relative to one another by approximately halfthe acceptance angle 133, between which a base 141 joining the legs 140extends. The legs 140 form another slide track 143 on one of thelongitudinal end faces 142 directed towards the cylinder contour 132 andextending parallel therewith. The width of the leg 140 measuredperpendicular to the cutting plate 14 is greater than a width of thebase 141, so that, by providing an approximately trapezoidal plate 144,the path of the slide element 127, the legs 140 and the plate 144 isflat. By preference, the plate 144 is locked on the base 141 and betweenthe two legs 140 by means of a connecting element known from the priorart.

A guide track 145 formed by the projection 131 and the two oppositelylying slide tracks 137 and 143 encloses and guides a longitudinallydisplaceable slide block 146. On a longitudinal end face directedtowards the slide track 137, the slidable plate-shaped slide block 146has an inclined positioning surface 147 running parallel with the slidetrack 137, the slide block 146 being free to effect a relativedisplacement of the tool 16 located on the slide element 127 by means ofthe drive system 148 in the direction of double arrows 149 and 150. Atleast one longitudinal scale bar 151 co-operates with the slide blocks146 and is preferably mounted on the top face of the legs 140, servingas an indicator for the displacement path along double arrows 149 and150. The plate 144, detachably and/or non-detachably mounted on the base141 and/or the cutting plate 14, having a recessed compartment 152disposed in the direction of the axis of symmetry 136, has a threadarrangement 154 with a threaded spindle 153 projecting through it in theregion of the base surface of the compartment 152 towards the slideblocks 146.This may be a high-precision threaded spindle or a pre-tensedthreaded spindle 153, etc., which enables the tool 16 to be preciselydisplaced or positioned relative to the roll 125 due to itshigh-precision finish. Clearly, it would also be possible to use cheaperthreaded spindles 153, the clearance of which could be compensated bymeans of a spring system, not illustrated, disposed between the slideblock 146 and the plate 144. Due to the accessibility afforded via thecompartment 152, the torque needed to displace the slide blocks 146 canbe applied. The option of providing the separate in-feed of the twoslide blocks 146 permits an asynchronous displacement of the tool 16perpendicular to the axis of symmetry 135.

It has been found to be of particular advantage if an angle ofinclination 155 formed by the slide block 146 provides a transmissionratio dependent on gradient such that even if the displacement path ofthe slide blocks 146 is short, the displacement path of the tool 16 canbe adjusted in proportion to the transmission ratio. A design of thistype considerably reduces the overall size of the drive system 148,slide element 127 and counter plate 139 as a unit.

Clearly, it would also be possible to provide only one slide block 146,also mechanically operated. Another drive system 148, not illustrated,may be provided, for example in the form of a counter-running threadedspindle 153 with slide blocks 146 displaceable in the opposite directionand locked thereon which would move towards or away from one anotherdepending on the drive direction. The advantage of this design is thesynchronous drive of the two slide blocks 146 and hence the uniformin-feed in both directions along the double arrows 149 and 150. Inprinciple, the distance 134 can be manually and/or automatically and/orsemi-automatically adjusted by any drive systems 148 known from theprior art, such as cranks, levers, etc., or may be operated by electric,hydraulic or pneumatic drives.

Clearly, it would also be possible to set up a digital control system,which would incorporate the control specifications linking theindividual axes for displacing the tool 117 and process the signals in acontrol system accordingly, so that positioning for the distance 134 canbe set, accurately repeated and adjusted.

As may also be seen from FIG. 23, the cutting plate 14 is fitted withthe cutting device 113 with two plate-shaped cutting elements 157, 158detachably and/or non-detachably mounted on a holder 156 and/or thecutting plate 14. By preference, the cutting device 113 is positionedalong the axis of symmetry 136 and downstream of the adjusting mechanism106. The cutting device 113 may naturally be positioned at any point ofthe cutting plate 14 and/or including on an external device, notillustrated. In practical terms, one cutting element 157 joined to theholder 156 and/or the cutting plate 14 extends flush with the top face111 of the cutting plate 14 and the other cutting element 158 is setback in the direction perpendicular to the axis of symmetry 136. Thecutting device 113, which is preferably remotely operable, may be builton and/or integrated in the cutting plate 14.

The holder 156 is provided in the form of a cross member 159 arrangedlengthways in a clearance of the cutting plate 14, which holds thecutting element 154 on the top face 111. As may also be seen in thisembodiment, the holder 156 co-operates with a drive system 160,co-operatively connected to the cutting element 158, which enables arelative displacement of the cutting element 158 towards the cuttingelement 157. In this case, the drive system 160 is provided in the formof a hydraulic unit, a cross member 161 which receives the cuttingelement 158 being guided along two track rods 162 spaced at a distanceapart. A cutting edge 163 formed by the cutting element 157 projects atleast partially beyond a cutting edge 164 of the cutting element 158 inthe operated state. On an end face surface 165 directed towards thecutting element 158, the plate-shaped cutting element 157 has atriangular shaped clearance 166 formed by the two cutting edges 163running at an incline towards one another, the acceptance angle 167 ofwhich corresponds for practical purposes to the acceptance angle 133.The cutting element 158 lying opposite the cutting element 157, having arecessed, plate-shaped end face surface 168, has an apex 169 formed bytwo cutting edges 164 running at an incline towards one another, thecutting edges 164 extending parallel with the cutting edges 163. On thebase of the apex 169, the oppositely lying end regions of the cuttingedges 164 have an oblique boundary edge 170 preferably extendingperpendicular to the axis of symmetry 136. The component 2 requiringfurther processing can be placed on a bearing surface 171 directedtowards the cutting element 157 and aligned perpendicular to theboundary edge 170. Clearly, the cutting device 13 may be provided in theform of a cutting element 157 and a guide element, in which case thecutting element 157 is provided with the cutting edges 163 and the guideelement merely acts as a stop during the cutting process. The cuttingedges 163 and 164 formed by the cutting elements 157 and 158 may beformed at least in part by the end face surface 165 and 168 of thecutting element 157 and 158 and/or by locked inserts. The majoradvantage of locked inserts is that locking inserts can be changedeasily and rapidly incurring low tool costs.

For practical reasons, only one cutting element 158 is displaceable andis displaced by means of the drive system 160 relative to the cuttingelement 157, which is preferably permanently fixed. The drive system 160may naturally be selected form any of the drive systems known from theprior art, for example hydraulic, pneumatic, electro-hydrauliccylinder-piston system, electric actuator drives, etc.. Clearly bothcutting elements 157 and 158 could also be displaceable relative to oneanother and/or could be arranged so that a displaceable cutting element157 or 158 cooperates with a stationary cutting element 158 or 157.

FIGS. 24 and 25 provide a detailed illustration of the corner-shapingdevice 4. The plate-shaped tool 16 is positioned by means of thecentring bolt 24 on the slide element 127, which is displaceablerelative to the cutting plate 14, and is secured by means of at leastone fixing screw 172. The tool 16 forms the shaping surfaces 36. Thetool 16 is essentially of a square-shaped basic contour, the centringbolt 24 being disposed centrally relative to the shaping surfaces 36which are arranged perpendicular to one another, as a result of whichthe tool 16 can be used in positions pivoted respectively by 90 degreesabout the centring bolt 24 or about a vertically extending pivot axis173, without changing the position relative to the slide element 127. Tothis end, the tool 16 has at least four mountings 174 for the fixingscrews 172 assigned to the corner regions. This enables the shapingsurfaces 36 to be made to different designs in terms of their roundingor structure in order to be able to shape different corner regions 10 onthe box-shaped component 2.

In order to shape the corner region 10 and make the side walls 8, thepre-formed component 2 is placed against the shaping surfaces 36 of thetool 16 and fixed to the tool 16 by the clamping device 62. The clampingdevice 62 consists of a clamping plate 175, which is immovably joined tothe safety door 109, for example, and displaced in conjunctiontherewith. In order to produce sufficient clamping force, anotherclamping element 176 is provided, for example, which may be apressurised clamping cylinder 177 applying a clamping force in thedirection of the tool 16 or the component 2 placed on the tool 16.

Once the component 2 has been sufficiently clamped on the tool 16, thecorner region 10 is shaped by displacing the roller system 42 in theguide elements 118 in the direction of arrow 178 and into the endposition of the roller system 42 shown in FIG. 25, during which processthe corner region 10 is shaped and lies against the shaping surface 36of the tool 16 by means of a resultant projection. The decisive factorin producing the exact shaping of the corner region 10 is to ensure thatthe distance 134 between the shaping surface 36 and the outline of thecylinder contour 132 is adjusted exactly. Exact corner shaping isproduced by setting the distance 134 to the lowest nominal dimension ofa thickness 179 of the component 2.

It is also of crucial importance that a distance 180 between a frontedge 181 of the clamping plate 175 directed towards the roller system 42and the cylinder contour 132 of the roller system 42 is only a fewtenths of a millimeter. This avoids any counter forming of the cornerregion 10 of the box-shaped component 2. By setting the distance 134 tothe lowest nominal dimension of the corner 179 of the component 2, anytolerance limits there might be can be compensated and the corneraligned exactly at a right-angle in the corner region 10 of thecomponent 2. A positive tolerance of the thickness 179 causes thecomponent 2 to be roll-formed in the corner region 10 between theshaping surface 36 of the tool 16 and the roller system 42.

The distance 134 between the shaping surface 36 and the roller system 42is adjusted by means of the adjusting mechanism 112, by means of whichthe sliding element 127 can be adjusted relative to the cutting plate 14and to the roller system 42. A central plane running perpendicular tothe cutting plate 14 along which the roller system 42 is displaced and aminimum diameter 182 of the dual-cone roller system 42 in the cornerregion 10 acts as a reference measurement.

As illustrated in FIG. 25 for example, in order to produce perfectlyformed corners, a spray nozzle 183 co-operating with the clamping plate175 is also provided, supplied via a line 184 with lubricating andcoolant fluid so that lubricating and coolant fluid can be applied priorto the forming process, in particular to an inclined surface of theclamping plate 175, from where this lubricating and coolant fluid istransferred to the shaping region by force of gravity. Since thesmallest of quantities will suffice and too large quantities are to beavoided in any case, the lubricating and coolant fluid is applied via ametering device, not illustrated, of the spray nozzle 183.

FIGS. 26 and 27 provide a detailed illustration of the cutting device113 of the corner-shaping device 4. On the cutting plate 14, thestationary cutting element 157 is detachably secured by a bottom face186 extending parallel with the cutting plate 14, e.g. at a distance 187from the cutting plate 14 by means of a spacing batten 185. Accordingly,the cutting element 157 acts as a cutting edge 163 projecting beyond thespacing batten 185 in the direction of the displaceable cutting element158, formed by the bottom face 186 and an end face 188 extendingperpendicular to the cutting plate 14. The distance 187 corresponds moreor less to a thickness 189 of the displaceable cutting element 158,which is guided on the cutting plate 14 in a linear displacement drivenby the drive system 160, e.g. a pressurised cylinder, and forms thecutting edge 164 with the front end face 168 and a top face 190.

On an end face 188, the cutting element 157 is provided with a V-shapedcut-away 191 adapted to the corner region 10 of the component 2 to becut, directed towards the cutting element 158. The displaceable cuttingelement 158, on the other hand, has a nose-shaped projection 192opposite the stationary cutting element 157 which is of the same shapeas the cut-away 191 and forms the front end face 168. Clearly, thecut-away 191 has an internally rounded contour in the corner region 10adapted to the component 2 and the projection 192 has a matchingexternally rounded contour.

When shaping the corners, in order to trim and remove the projection 194standing out from the resultant end faces 193 of the side walls 8 in thecorner region, the component, with its opening directed towards thedisplaceable cutting element 158, is manually positioned with the endfaces 193 flat against the latter and the corner region 10 in thecut-away 191. When the cutting element 158 is displaced by the drivesystem 160 towards the stationary cutting element 158, an exact cut ismade flush along the end faces 193 of the component 2 in the cornerregion 10, thereby removing the projection 194.

A cutting device 113 of this type does not necessarily have to bemounted directly on the system 101 but may be provided as a separate,detached cutting device 113.

FIG. 28 provides a schematic illustration of another embodiment of thecutting device 113. In this embodiment, the component 2 to be cut islaid on a base plate 195 with its opening and the side walls 8projecting upwards. Mounted opposite the base plate 195 is a carriagesystem 197 which can be displaced at a right angle towards the latter bymeans of drive 196. This carriage system 197 has a tool holder 198,which bears the stationary cutting element 157 and the cutting element158 displaceable by means of the drive system 160, the latter beingguided on the tool carriage 198 in a guide arrangement 199.

When the component 2 is placed on the base plate 195 in readiness forthe cutting process, an infeed is activated by the drive 196 of the toolholder 198 in the direction of arrow 200, until the displaceable cuttingelement 158 bears on the end faces 193 of the side walls 8 with a bottomface 201. The bottom face 201 of the displaceable cutting element 158 isaligned flush with a top face 202 of the stationary cutting element 157.The cutting position has therefore been reached 1and the displaceablecutting element 158 is displaced via the drive system 160 in thedirection of arrow 203 and hence towards the stationary cutting element157 until the side wall 8 of the component 2 bears on the end face 188of the stationary cutting element 157. As displacement continues in thedirection of arrow 203, the projection 194 produced when shaping thecorner is trimmed exactly flush with the end faces 193 due to theco-operation of the cutting edges 163, 164 with the cutting elements157, 158. After the cutting process, the tool holder 198 is displaced bythe drive 196 in the direction opposite arrow 200 into an open positionat a distance from the base plate 195, after which the component 2 canbe removed from the cutting device 113.

As may also be seen from FIGS. 26 and 27 described above in relation tothe cutting device 113, as the projection 194 is trimmed, an exactlyflush path to the end faces 193 of the side walls 8 is achieved due tothe fact that bearing elements 205 forming guide surfaces 204 areprovided, either on the cutting plate 14 or separately from it or fromthe machinery 101, on which the component is laid by its end faces 193of the side walls 8 and in its corner region 10 with the projection 194projecting between the cutting elements 157, 158. The cutting elements157, 158 are arranged so that the cutting edge 163 of the cuttingelement 157 and the cutting edge 164 of the cutting element 158 aredisposed running in the guide surface 204 formed by the bearing elements205. As the cutting process proceeds, i.e. by displacing thedisplaceable cutting element 158 relative to the stationary cuttingelement 157, the projection 194 standing out by a height 206 of the sidewalls 8 is trimmed exactly flush in order to achieve the height 206 ofthe side walls 8, even in the corner region 10, without any discrepancy.

As may also be seen from the broken lines of FIG. 27, another option isto provide the displaceable cutting element 158 with bearing elements205 on it in the form of projections, so that the component 2 issupported by its side walls 8 in the immediate vicinity of the cornerregion 10 to be cut.

Turning back to FIG. 23, the roller system 42 consists of a roll 125 inbearings 207 of a rotatably mounted mounting frame 208. Accordingly, asupport frame 209 is provided, which can be displaced in the guideelements 118 by means of the drive unit 126 in a direction perpendicularto the cutting plate 14, forming a guide housing 210. The guide elements118 therefore form a guide device 211 for the guide housing 210. As aresult, the corner-shaping device 4 can be rapidly fitted with rolls 125of different designs, the cylinder contour 132 of which is adapted tothe corner region 10 that will be produced on the component 2. Thereplacement device 121 has fast-closing elements 122, e.g. levers 123,enabling the change to be made quickly and without the need for anycomplex tools.

As may also be seen from FIG. 25, a height 212 of the tool 16 or theperipheral shaping surfaces 36 is greater than the height 206 of theside walls 8 of the component 2. In any event, the height 212 of theshaping surfaces 36 amounts to a measurement corresponding to the height206 of the side walls 8 plus an anticipated height 213 of the projection194. As a result, this ensures that when shaping the corner region 10,the projection 194, once formed by the roll, will always lie flat in theregion of the shaping surfaces 36 and will not be drawn in against thebottom face of the tool 16 under any circumstances, which would resultin jamming, making it more difficult to remove the component 2 once thecorner region 10 had been formed.

FIG. 29 illustrates another embodiment of the roller system 42 with theclamping device 62, the same reference numbers being used to denote thesame components described above in respect of the other drawings.Provided in a guide device 107 arranged on the machine frame 104, e.g.two guide rods 220 extending perpendicular to the cutting plate 14 andspaced at a distance apart from one another, is a guide carriage 221which is mounted so as to be displaceable in a vertical directionrelative to the cutting plate 14. The guide carriage 221 is driven bymeans of an actuator cylinder 224 disposed in the machine frame 104 oron a cantilever 222 disposed opposite the cutting plate 14, for example,drivingly linked to the guide carriage 221 via a piston rod 223 andoperated by means of a pressurised medium, e.g. hydraulic oil.Naturally, it would be conceivable to use other types of drives to drivethe guide carriage 221, such as electrically driven spindle drives, etc.

A cartridge 226, which can be changed by means of the replacement device121, is retained in the guide carriage 221 by a U-shaped bracket 225. Inside arms 227, 228, this cartridge 226 provides a bearing for the roll125 so that it can rotate about the central axis 124 extending parallelwith the cutting plate 14. The side arms 227, 228 are arranged at adistance from the cutting plate 14 and are joined by means of a base arm229 extending parallel with the latter which abuts with a head plate 230of the guide carriage 221 arranged in parallel in order to transfer thecompression force applied by the actuator cylinder 224 in the directionof arrow 231 towards the cutting plate 14 to the cartridge 226 and roll124 as well as a clamping plate 232 of the clamping device 62, alsodisplaceably arranged in the cartridge 226.

The clamping plate 232 is displaceable perpendicular to the cuttingplate 14 and is guided by guide posts 233 in guide elements 234 disposedin the base arm 229, e.g. guide bushes 235. Between the clamping plate232 and the base arm 229, coil springs 236 of a spring arrangement 237enclose the guide posts 233, as a result of which a maximum distance 238between oppositely facing surfaces of the base arm 229 and the clampingplate 232 is achieved due to a corresponding abutting arrangementbetween the guide posts 223 and the base arm 229.

The clamping device 62 with the clamping plate 232 is arranged in thecartridge 226 relative to the roll 125 in such a way that the end faces181 of the clamping plate 232 directed towards the V-shaped contour ofthe roll 125 are set back by the distance 180, which is in the order ofapproximately {fraction (1/10)} mm.

A clamping surface 239 of the clamping plate 232 directed towards thecutting plate 14 is provided on the machine frame 104 and the plate part6 receiving the tool 16, provided as a means of shaping the cornerregion 10, in particular a shaping block 240, is provided on the cuttingplate 14, being displaceable and fixable relative to the internalcontour of the roll 125 directed towards it by means of its shapingsurface 96 facing the roll 125, as described in detail above withreference to the preceding drawing. It should also be pointed out thatthe shaping block 240 is pivotable, relative to a positioning pin 241arranged at the geometric centre point of the shaping block 240, thefixing arrangement of which is designed accordingly, respectively by 90°in a plane extending parallel with the cutting plate 14.

If a pre-formed plate part 6, on which the side walls 8 have beenpre-formed, e.g. by an edge-folding process, now requires shaping in thecorner region 10, it is laid on the shaping block 240 so that the sidewalls 8 and the corner region 10 overlap with the shaping surfaces 96 ofthe shaping block 240. In order to run the forming process of the cornerregion 10, the drive or the actuating cylinder 224, for example ispressurised, and the cartridge 226 together with the roll 125 and theclamping device 62 is displaced in the direction of the shaping block,as a result of which the clamping plate 232 clamps the plate part 6tightly against the shaping block 240. During the subsequentdisplacement of the cartridge 226 in the direction of arrow 231, thespring arrangement 237 of the clamping device 62 is compressed and thecompression force continuously increased until the roll 125, which inits starting position is on a higher level than the clamping surface239, effects the shaping process in the corner region 10 of the platepart 6, during which the irregularly pre-formed corner region 10 ispressed against the shaping surfaces 96 of the shaping block, therebyreaching the right-angled position of the adjoining side faces 8 in thecorner-region 10.

Finally, it should finally be pointed out that the individual parts andcomponents or groups of components of the embodiments described aboveare illustrated in a simplified schematic form. Furthermore, theindividual parts of the combinations of features incorporated in theembodiment described may be construed as independent solutions proposedby the invention.

In particular, subject matter relating to the individual embodimentsillustrated in FIGS. 1 to 15; 16; 17, 18; 19; 20; 21 a, 21 b; 22, 23;24, 25; 26, 27; 28 can be construed as independent solutions proposed bythe invention. The tasks and solutions can be found in the detaileddescriptions relating to these drawings.

List of Reference Numbers

S Sheet

2 Component

4 Corner-shaping device

6 Plate part

8 Side wall

10 Comer region

12 Frame

14 Cutting plate

16 Tool

18 Bearing block

20 Pin

22 Intermediate bearing

24 Centring bolt

26 Adjusting mechanism

28 Threaded spindle

30 Top face

32 Bottom face

34 Side face

36 Shaping surface

38 Cutting element

40 Drive system

42 Roller system

44 Cone parts

46 Drive system

48 Thrust face

50 Support plate

52 Top face

54 Bottom face

56 Internal face

58 Adjusting drive

60 Cutting edge

62 Clamping device

64 Drive mechanism

66 Excess piece

68 Edge-folding press

70 Main body

72 Die

74 Punch

76 Grooved region

78 Shaping region

80 Projection

82 Drive mechanism

92 Positioning device

92-1 Shaft section

92-2 Transmission member

94 Positioning mechanism

94-1 Means

94-2 Surface

94-3 Adjusting means

94-4 Motion control part

96 Shaping surface

96-1 Shaping surface

96-2 Shaping surface

96-3 Shaping surface

96-4 Shaping surface

98 Region

98-1 Grooved region

98-2 Grooved region

101 System

103 Stand surface

104 Machine frame

105 Bearing frame

107 Guide device

108 Locking device

119 Safety door

111 Top face

112 Adjusting mechanism

113 Cutting device

114 Width

115 Length

118 Guide elements

119 Connecting device

120 Supporting element

121 Replacement device

122 Fast-closing element

123 Lever

124 Central axis

125 Roll

126 Drive unit

127 Sliding element

128 Longitudinal end faces

129 Top face

130 Bottom face

131 Projection

132 Cylinder contour

133 Acceptance angle

134 Distance

135 Axis of symmetry

136 Axis of symmetry

137 Slide track

138 Angle

139 Counter plate

140 Leg

141 Base

142 Longitudinal end face

143 Slide track

144 Plate

145 Guide track

146 Slide block

147 Positioning surface

148 Drive system

149 Double arrow

150 Double arrow

151 Longitudinal scale bar

152 Compartment

153 Threaded spindle

154 Thread arrangement

155 Angle of inclination

156 Holder

157 Cutting element

158 Cutting element

159 Cross member

160 Drive system

161 Cross member

162 Track rod

163 Cutting edge

164 Cutting edge

165 Front end face

166 Reset

167 Angle of acceptance

168 End face surface

169 Apex

170 Boundary edge

171 Bearing surface

172 Fixing screw

173 Pivot axis

174 Mounting

175 Clamping plate

176 Clamping element

177 Clamping cylinder

178 Arrow

179 Thickness

180 Distance

181 Front edge

182 Diameter

183 Spray nozzle

184 Line

185 Spacing batten

186 Bottom face

187 Distance

188 End face

189 Thickness

190 Top face

191 Cut-away

192 Carriage system

193 End face

194 Projection

195 Base plate

196 Drive

197 Carriage system

198 Tool holder

199 Guide arrangement

200 Arrow

201 Bottom face

202 Top face

203 Arrow

204 Guide face

205 Bearing element

206 Height

207 Bearing

208 Mounting frame

209 Support frame

210 Guide housing

211 Guide device

212 Height

213 Height

220 Guide rods

221 Guide carriage

222 Cantilever

223 Piston rod

224 Actuating cylinder

225 Contour

226 Cartridge

227 Side arm

228 Side arm

229 Base arm

230 Head plate

231 Arrow

232 Clamping plate

233 Guide post

234 Guide element

235 Guide bush

236 Coil spring

237 Spring arrangement

238 Front edge

239 Clamping surface

240 Shaping block

241 Positioning pin

What is claimed is:
 1. A method of forming a corner region bounded onthree sides from a flat plate having side edges having longitudinalextensions, comprising the steps of (a) folding down the side edges ofthe flat plate by a predetermined height from the plane of the flatplate and across at least a major part of the longitudinal extensions toform side walls in the corner region in a three-dimensional curvedtransition region, (b) clamping the transition region between a toolhaving a predeterminable, three-dimensional external shape, of thecorner to be formed and a height-adjustable clamping plate pressedagainst the flat plate, (1) the external shape of the tool beingcomprised of shaping surfaces having a height same as or slightly largerthan a height of the side walls plus a height of an excess projection inthe corner region and to be trimmed, the clamping plate having frontedges cooperating with the shaping surfaces of the tool forming thecorner region, (2) Positioning the front edges flush with the shapingsurfaces of the tool or protecting therefrom by a distance slightlysmaller than the thickness of the side walls, (c) shaping the transitionregion by means of at least one roller system overlapping the cornerregion between the side walls by pressing in the curved transitionregion against the tool.
 2. The method of claim 1, wherein a distancebetween the shaping surfaces of the tool and a cylindrical contour ofthe roller system, and extending perpendicularly to the shaping surfacesis at most equal to the thickness of the side walls.
 3. The method ofclaim 2, further comprising the step of adjusting the tool and theclamping plate to obtain the distance between the shaping surfaces ofthe tool and the cylindrical contour of the roller system.
 4. The methodof claim 2, further comprising the step of adjusting the cylindricalcontour of the roller system to obtain the distance between the shapingsurfaces of the tool and the cylindrical contour.
 5. The method of claim1, further comprising the steps of affixing the clamping plate to asafety door delimiting a working region, and adjusting the distance ofthe clamping plate with the safety door relative to the flat plate. 6.The method of claim 5, further comprising the step of applying theclamping plate against the tool by a clamping element actuatableindependently of the adjusting of the distance of the clamping platewith the safety door relative to the flat plate whereby a compressionforce is exerted in the direction of the tool.
 7. The method of claim 1,wherein the shaping surfaces of the tool intersect at tool corners,further comprising the step of providing a roller of the roller systemat each tool corner.
 8. The method of claim 1, further comprising thestep of providing a respective one of the clamping plates at each toolcorner.
 9. A device for forming a corner region bounded on three sidesfrom a flat plate having a top face and side walls folded down from sideedges of the flat plate by a predetermined height and across at least amajor part of the longitudinal extension, which comprises (a) a rollersystem, for forming the corner region in a three-dimensional shape, (b)a tool having a predeterminable, three-dimensional external shape, (1)the external shape of the tool being comprised of a top face and shapingsurfaces having a height corresponding to the predetermined height ofthe side walls plus a height of an excess projection extending from theside walls and to be trimmed, and (c) a clamping device displaceable ina direction substantially perpendicular to the top face of the tool forclamping the flat plate to the top face of the tool, the clamping platehaving front edges cooperating with the shaping surfaces of the toolforming the corner region, and (1) the front edges being flush with theshaping surfaces of the tool or projecting therefrom by a distanceslightly smaller than the thickness of the side walls.
 10. The device ofclaim 9, wherein the roller system comprises a roll rotatably mounted ina bearing fixed in a mounting frame, a support frame having guideelements for replaceably inserting a guide housing in a guide device,the guide housing being displaceable relative to the tool by means of adrive system, and a replacement device receiving the guide device, thereplacement device having elements for clamping the support frame in acorrect position in the guide housing.
 11. The device of claim 9,further comprising shaping sections on the top face of the tool indifferent corners thereof, the shaping sections at the different cornershaving different dimensions.
 12. The device of claim 9, wherein theroller system and the clamping device form a jointly displaceableshaping and clamping unit, further comprising a common drive fordisplacing the unit.
 13. The device of claim 9, further comprising acartridge housing the roller system and the clamping device and a guidecarriage retaining the cartridge for rapid replacement of the cartridge.14. The device of claim 13, wherein the clamping device comprises aclamping plate mounted on guide posts in the cartridge for displacementagainst the bias of a spring arrangement.